FABRIC AND METHOD FOR OBTAINING SAID FABRIC

Abstract

A method for producing a combustion resistant upholstery fabric with a weight of approximately 180-210 g/m.sup.2 includes: at least one preparation step of an intimate blend yarn with 65% by weight of polyester fibers and 35% by weight of cotton fibers, at least one weaving step with a 2/1 twill weave of the yarn thus prepared to obtain a fabric, at least one washing step of said fabric to obtain a bleached fabric, at least one step of pressing said bleached fabric, the pressing step involves inserting said bleached fabric inside at least one calender to obtain an upholstery fabric.

Claims

1. Method for producing a combustion resistant upholstery fabric with a weight of approximately 180-210 g/m.sup.2, said method comprising: at least one preparation step of an intimate blend yarn with 65% by weight of polyester fibers and 35% by weight of cotton fibers, at least one weaving step with a 2/1 twill weave of said yarn thus prepared to obtain a fabric, at least one washing step of said fabric to obtain a bleached fabric, at least one step of pressing said bleached fabric, said at least one pressing step involves inserting said bleached fabric inside at least one calender to obtain an upholstery fabric.

2. The method according to claim 1, wherein the upholstery fabric obtained following said at least one pressing step has a lower weight than the weight that said fabric has before being subjected to said at least one pressing step.

3. The method according to claim 1, wherein the at least one weaving step is carried out with an air jet loom.

4. The method according to claim 1, wherein the fabric obtained following said at least one weaving step, and before said pressing step, has a weight greater than about 200 g/m.sup.2.

5. The method according to claim 1, wherein, following said at least one pressing step, the obtained upholstery fabric has a weight of less than about 200 g/m.sup.2.

6. The method according to claim 1, wherein said at least one step of pressing said bleached fabric provides for hot calendering.

7. The method according to claim 1, wherein the method does not provide for the application of any flame retardant chemical salt to the fabric, and the fabric is not treated with brominated or phosphorus flame retardant materials.

8. The method according to claim 1, wherein said at least one washing step comprises at least a first sub-step of heat treatment by washing said fabric with caustic soda.

9. The method according to claim 8, wherein said at least one washing step comprises at least a second heat treatment sub-step by washing said fabric with sodium hypochlorite and/or with hydrogen peroxide and/or with optical brighteners.

10. The method according to claim 1, wherein said at least one preparation step provides: at least one blending sub-phase, in which polyester fibers and cotton fibers are mixed; a spinning sub-phase, in which said polyester fibers and/or said cotton fibers are spun together thus forming a yarn.

11. The method according to claim 1, further comprising, following said at least one washing step, at least one drying step.

12. The method according to claim 11, wherein in said at least one drying step said bleached fabric is dried by irradiation at a temperature between 150 C. and 200 C.

13. The method according to claim 11, wherein in said at least one drying step a stenter is used internally equipped with means suitable for mechanically retaining the fabric in a taut configuration during the at least one drying step.

14. The method according to claim 1, wherein said at least one pressing step provides for passage of said bleached fabric between heated and counter-rotating rollers of said calender, in which said rollers are heated to a temperature higher than 150 C., at a pressure higher than 200 kg/cm.sup.2.

15. (canceled)

16. The method according to claim 1, wherein said upholstery fabric obtained following said at least one pressing step is equipped with air permeability which allows an air flow passage of less than 55 mm/s, at a pressure of 200 Pa.

17. Combustion resistant upholstery fabric comprising a calendered fabric of an intimate blend yarn of 65% by weight polyester fibers and 35% by weight cotton fibers, with a 2/1 twill weave and having a weight of about 180-210 g/m.sup.2.

18. Multilayer lining and/or containment lining, suitable for containing and/or lining a padding or filling material, comprising a combustion-resistant upholstery fabric the fabric comprising a calendered fabric of an intimate blend yarn of 65% by weight polyester fibers and 35% by weight cotton fibers, with a 2/1 twill weave and having a weight of about 180-210 q/m.sup.2 and/or comprising an upholstery fabric obtainable by the method according to claim 1.

19. Cushion or other piece of furniture, which is covered or lined with a combustion resistant cover fabric the fabric comprising a calendered fabric of an intimate blend yarn of 65% by weight polyester fibers and 35% by weight cotton fibers, with a 2/1 twill weave and having a weight of about 180-210 q/m.sup.2 and/or is covered or lined with a cover fabric obtainable by the method according to claim 1.

Description

DETAILED DESCRIPTION OF THE INVENTION AND OF SOME OF ITS PREFERRED EMBODIMENTS

[0036] The present invention is further clarified hereinafter in a preferred embodiment thereof reported for purely illustrative and non-limiting purposes.

[0037] The combustion-resistant upholstery fabric, advantageously obtainable with the method also object of the present invention, is preferably configured to be used to cover and/or line furnishing elements, preferably in soft or soft hand-made material, such as cushions that ad for example they are used in the production of furniture, and in particular of sofas and/or armchairs.

[0038] In particular, said furnishing elements, advantageously in soft hand material, can be made of polymeric foams, or more preferably they can be made of natural feathers, feathers and/or down or synthetic material, such as virgin polyester fibers or recycled.

[0039] Conveniently, the combustion-resistant upholstery fabric according to the invention can be preferably used to make a lining layer which is preferably internally directly in contact with the material that forms the piece of furniture to be lined and/or covered.

[0040] Conveniently, the combustion-resistant upholstery fabric according to the invention can preferably be used to make a lining layer which can be externally the visible one and/or can come into direct contact with the user of the furniture element Advantageously, the combustion-resistant upholstery fabric according to the invention can be preferably used to make a lining layer which can be externally covered by a further layer, for example in fabric, which can face towards the external environment, ie it can be the one configured to make contact with a user of the furniture.

[0041] The method for the production of an upholstery fabric resistant to combustion and with a weight of about 180-210 g/m.sup.2, object of the present invention, comprises: [0042] at least one preparation step of an intimate blend yarn with 65% by weight of polyester fibers and 35% by weight of cotton fibers, the [0043] at least one phase of weaving with a twill weave 2/1 of said yarn thus prepared to thus obtain a fabric, [0044] at least one washing step of said fabric to obtain a bleached fabric; [0045] at least one step of pressing said bleached fabric, preferably by hot calendering; in particular, the pressing step involves inserting said bleached fabric inside at least one calender to obtain an upholstery fabric.

[0046] Preliminarily, as said, the method according to the invention provides at least one step for preparing a yarn, which comprises at least a percentage by weight of polyester of 65% and at least a percentage by weight of cotton of 35%.

[0047] More in detail, the aforesaid preparation step provides for the realization of the aforesaid yarn, by means of at least one mixing sub-step, in which polyester fibers and cotton fibers are mixed.

[0048] Preferably, the mixing step involves mixing together longitudinal fibers of cotton and polyester, to create a single yarn or a bundle of fibers, the complex of which is called, in technical jargon, polycotton.

[0049] The preparation phase therefore advantageously provides for a spinning sub-phase in which said polyester fibers and/or said cotton fibers are spun together forming said yarn.

[0050] Conveniently, the yarn is composed of cotton fibers mixed in an intimate blend with polyester fibers.

[0051] Suitably, the yarn comprises about 65% by weight of polyester and about 35% by weight of cotton.

[0052] Suitably, the yarn comprises about 65% by weight of polyester fibers and about 35% by weight of cotton fibers. This ratio between polyester fibers and cotton fibers is optimal as it allows the fabric thus made to be resistant to combustion and in particular to comply with sector regulations, and more in detail to overcome, without the use of fireproofing chemicals, the so-called California test, ie the test described in California TB (Technical Bulletin) 117: 2013section 2.

[0053] Advantageously, the yarn can be carded or combed yarn.

[0054] Conveniently, the polyester used, both for making the fabric according to the invention, and for making the element in soft material can be recycled.

[0055] The method therefore involves a weaving phase of the previously prepared yarn by means of a twill or 2/1 twill weave.

[0056] Advantageously, by weaving by twill weave is meant a weaving which allows to obtain a fabric in which the warp threads bind the wefts proceeding with a diagonal course.

[0057] Conveniently, the yarn is woven with a 2/1 twill weave, ie the weaving of which has diagonal lines, in which one face (called right or technical face) has a different conformation from the other face (called reverse or technical rear). Conveniently, in fact, from one side of the fabric the warp threads pass twice over the weft and once under it, while the opposite occurs on the other side. In particular, the twill weave designated with the fraction 2/1 indicates that two harnesses are raised (and therefore there are two crossed threads) while only one harness is lowered when a weft thread is inserted.

[0058] The weaving with 2/1 twill weave is particularly advantageous, indeed optimal, as the resulting weave is particularly dense and the holes between the threads allow to avoid the leakage of the material to be covered or filling (in particular in the case of feathers or other padding).

[0059] Advantageously, the yarn used for weaving can have a thickness of 30 NE (Number English) in the warp and 20 NE (Number English) in the weft.

[0060] Advantageously, the fabric obtained following the weaving step can be provided with an open or closed selvedge.

[0061] Preferably, the weaving step is carried out with an air-jet loom, i.e. a loom without shuttle which uses a jet air current to pull the weft thread through the shed. Conveniently, the operating principle envisages using air as a means for inserting the weft into the warp. More in detail, a compressed air flow is used to pull a weft thread by means of a frictional traction force generated between the thread itself and the air flow. For this purpose, the jet/air flow generated by the air-jet frame is used to achieve the purpose.

[0062] Preferably, said at least one weaving step is configured to obtain with said yarn a fabric with a twill weave 2/1 and having a weight of about 180-210 g/m.sup.2.

[0063] Advantageously, the raw fabric (i.e. the fabric obtained following the weaving step) can have a weight greater than about 200 g/m.sup.2, preferably about 205 g/m.sup.2.

[0064] Advantageously, the raw fabric has a width, transversely with respect to its prevailing direction of development, of about 170 cm or about 330 cm.

[0065] Preferably, following the preparation phase, the method provides for a sewing phase, to sew the various pieces of fabric (ie technical term to identify portions of the fabric) to thus produce reels of fabric, preferably with a length of between 5 and 10 km.

[0066] The method according to the invention further provides for at least one washing step of said fabric to obtain a bleached fabric.

[0067] In accordance with a preferential embodiment of the present invention, said washing step comprises at least a first sub-step of heat treatment by washing said fabric with caustic soda.

[0068] Advantageously, moreover, said washing step comprises at least a second heat treatment sub-step by washing said fabric with sodium hypochlorite and/or with hydrogen peroxide and/or with optical brighteners.

[0069] Conveniently, the first washing sub-phase using caustic soda is called the purging sub-phase and the second washing sub-phase using sodium hypochlorite and/or hydrogen peroxide and/or optical brighteners is called the bleaching sub-phase.

[0070] Following the washing phase, the cotton used in the yarn obtains the desired white color.

[0071] Advantageously, the cotton used in the yarn can have limited contamination from external fibers and, in particular, the cotton used can be known as contamination-controlled (CC).

[0072] The method preferably comprises, following said washing step, at least one drying step. Preferably, in said drying step said bleached fabric is dried by irradiation at a temperature higher than 150 C. and preferably between 150 C. and 200 C.

[0073] More in detail, preferably, the drying step is carried out in a stenter equipped internally with holding means, for example grippers or the like, capable of mechanically retaining the fabric in a taut configuration during the drying step itself.

[0074] The method according to the invention further comprises at least one step of pressing said bleached fabric, preferably by hot calendering. In particular, the pressing step involves inserting said bleached fabric inside at least one calender to obtain an upholstery fabric. Advantageously, following the pressing step, the upholstery fabric can have a weight lower than about 200 g/m.sup.2, preferably about 188 g/m.sup.2.

[0075] The upholstery fabric obtained following said pressing step has a lower weight than the weight that said fabric has before being subjected to said pressing step.

[0076] Conveniently, the upholstery fabric according to the invention has a weight of about 180-210 g/m.sup.2 and this is particularly advantageous, indeed optimal, since on the one hand it allows to avoid the leakage of the material to be covered or filling (in particularly in the case of feathers or other padding) and at the same time, on the other hand, avoids having a fabric that is too rigid and that generates an unwanted noise following its contact, thus resulting not suitable for the upholstery (in particular for the upholstery a cushion of an armchair, sofa or other soft or upholstered piece of furniture).

[0077] Advantageously, said pressing step provides for the passage of said bleached fabric between heated and counter-rotating rollers of said calender, in which said rollers are heated to a temperature higher than 150 C., and more preferably equal to about 190 C., at a higher pressure of about 200 kg/cm.sup.2, and preferably at a pressure of about 295 kg/cm.sup.2.

[0078] The pressing step has the advantageous purpose of reducing the thickness and/or reducing the size of the holes present in the weave of the fabric.

[0079] Furthermore, the hot calendering step is particularly advantageous as it allows the light dissolution of the polyesterfibers of the fabric yarn, thus preventing the internal element to be lined (for example the feathers) from coming out outside the lining made with said tissue.

[0080] Preferably, the upholstery fabric obtained following the pressing step has a width, transversely with respect to the main development direction, of between 140 cm and 180 cm and preferably of about 160 cm.

[0081] Advantageously, said upholstery fabric obtained following said pressing step is provided with air permeability which allows an air flow passage of less than 55 mm/s at a pressure of 200 Pa.

[0082] Preferably, said upholstery fabric obtained following said pressing step is provided with air permeability which allows an air flow passage of about 40 mm/s at a pressure of 200 Pa.

[0083] The method according to the invention does not provide for the application on the fabric of any flame retardant chemical salt, and in particular the fabric is not treated with brominated or phosphorus flame retardant materials.

[0084] The present invention also relates to an upholstery fabric which can be advantageously obtained by means of the method described up to now.

[0085] The combustion-resistant upholstery fabric according to the invention comprises a calendered fabric, preferably hot, and provided with at least a percentage by weight of polyester and at least a percentage by weight of cotton, in which the percentage by weight of polyester is greater than percentage by weight of cotton. Preferably, the combustion-resistant upholstery fabric according to the invention comprises a calendered fabric, preferably hot, and obtained with an intimate blend of polyester and cotton fibers, preferably in which the percentage by weight of the polyester is about 65% while the percentage by weight of cotton fibers is about 35%. Preferably, the cover fabric is woven with a 2/1 twill weave. Preferably, the upholstery fabric according to the invention has a weight lower than about 200 g/m.sup.2, preferably about 188 g/m.sup.2. Conveniently, the upholstery fabric according to the invention is completely free of flame retardant chemical salts.

[0086] Advantageously, the upholstery fabric can have a warp with an average of about 49 threads per cm.

[0087] Advantageously, the upholstery fabric can have a weft with an average of about 30 strokes per cm.

[0088] Advantageously, the combustion resistant upholstery fabric according to the invention is not treated with flame retardant materials, and in particular it is not treated with brominated flame retardant materials (measured according to the UNI EN ISO 17881-1: 2016 standard) such as:

TABLE-US-00001 2-Monobromobiphenyl (PBB1) CAS No 2052-07-5 2,5-Dibromobiphenyl (PBB9) CAS No 57422-14-2 2,2,5-Tribromobiphenyl (PBB18) CAS No 59080-34-1 2,2,4,5-Tetrabromobiphenyl (PBB49) CAS No 60044-24-8 Pentabbromo-1,1-biphenyl (PBB103) CAS No 14910-04-4 2,2,3,3,4,4,5,5-Hexabromobiphenyl (PBB153) CAS No. 59080-40-9 Heptabromo-1,1biphenyl (PBB180) CAS No. 88700-06-05 2,2,3,3,4,4,5,5-Octabromobiphenyl CAS No. 67889-00-3 2,2,3,3,4,4,5,5,6-Nonabromobiphenyl CAS No. 69278-62-2 Decabromobiphenyl PBB209 CAS No. 13654-09-6 Pentabromodiphenylether BDE99 CAS No. 32534-81-9 Decabromodiphenylether BDE209 CAS No. 1163-19-5 Hexabromocyclododecane HBCDD CAS No. 3194-55-6 2,2,4,4-Tetrabromodiphenylether BDE47 CAS No. 5436-43-1 2,2,3,4,4,5,6-Hexabromodiphenylether BDE154 CAS No. 207122-15-4 2,23,4,4,5,6-Heptabromodiphenylether BDE183 CAS No. 207122-16-5 2,2,3,4,4,5,5,6-Octabromodiphenylether CAS No. 337513-72-1 BDE203

[0089] or phosphorus flame retardants (measured according to UNI EN ISO 17881-2: 2016), such as:

TABLE-US-00002 TRIS Tris (2,3-dibromopropyl) phosphate CAS 126-72-7 TCEP Tris (2-chloroethyl) phosphate CAS 115-96-8 TDCPP Tris (1,3-dichloro-2propyl) phosphate CAS 13674-87-8 TCPP Tris (1-chloro-2-propyl) phosphate CAS 13674-84-5 TBBPA Tetrabromobisphenol A CAS 79-94-7

[0090] In order to better evaluate the properties of the fabric according to the invention, the same is been subjected to torsion tests, with the following results:

TABLE-US-00003 Test carried out measurement unit obtained value Average rpm 771 14 Average rpm 19.6 Direction of twist Z Variation coefficient % 3.20 Torsion coefficient alpha 108

TABLE-US-00004 Test carried out measurement unit obtained value Average torsion rpm 621 13 Average torsion rpm 15.8 Direction of torsion Z Variation coefficient % 3.80 Torsion coefficient alpha 106

TABLE-US-00005 Test method ISO 17202: 2002 Ambient and test in normal (20 2) C. .Math. (65 4)% atmosphere RH Test equipment Twist meter Conditions of the wire white Pretension applied 10 cN per warp, 15 (cN per weft) Length test useful (500 1) mm Elimination of non-fibrous materials no Number of test tubes analyzed 15 per direction

[0091] The subject of the present invention also forms a cushion or other piece of furniture, preferably for furniture such as sofas and/or armchairs, which is covered or lined with a combustion resistant upholstery fabric as described above and/or obtainable with the method according to the invention as described above. Conveniently, said cushion comprises an internal element made of soft material (which thus defines the padding material) which is externally covered by a cover which is made entirely, or at least in part, with a combustion-resistant cover fabric as described above and/or obtainable with the method according to the invention as described above.

[0092] Conveniently, the internal element made of soft material (which thus defines the padding material) of the cushion can comprise polymeric foams and/or feathers, natural or synthetic feathers and/or duvets.

[0093] Advantageously, an internal element made of soft material (such as for example non-flame retardant polyurethane foam with a density of 28 kg/m.sup.3) lined with a combustion resistant fabric according to the invention was subjected to a flame reaction test 15066 PADDED FURNITURE: OF FLAMMABILITY BY CIGARETTE according to the method described in California TB (Technical Bulletin) 117: 2013section 2.

Type of Fabric: Material Barrier/Interliner

[0094]

TABLE-US-00006 Number Tube 1 2 3 Total combustion of the cigarette (YES/NO) YES YES YES Duration of progressive combustion (without flame) 44 43 44 from the application of the source (min) Size of the damage to the Standard Type II 41 44 45 coating (mm) Presence of combustion WITH flame (YES/NO) NO NO NO TEST RESULT (PASS/FAIL) PASS PASS PASS

[0095] Conditioning of the sample and ignition source: 24 h 213 C., <55% relative humidity with ambient temperature and relative humidity measured during the test: 19 C., 44% relative humidity.

[0096] The fabric improved according to the invention and/or obtained with the method according to the invention is particularly advantageous in that it is resistant to combustion, and in particular complies with the regulations of the sector, and in more detail passes the test described in California TB (Technical Bulletin) 117: 2013section 2, and this is achieved without the use of fire retardant chemicals.

[0097] The present invention also relates to a multilayer lining and/or containment lining, capable of containing and/or lining a padding or filling material inside it. The multilayer lining can be made at least partially with a combustion-resistant upholstery fabric as described above and/or obtainable with the method according to the invention described above.

[0098] Conveniently, the multilayer lining can comprise/be for example a lining or the like.

[0099] Advantageously, the multilayer lining can be made by coupling the upholstery fabric according to the invention with at least a second material, known per se, and not described in detail below.

[0100] All the technical characteristics described with reference to the method and/or to the fabric must also be understood as described also with reference to the cushion and/or the multilayer covering and/or containment.

[0101] Unlike the methods described in JPH05171564, CN110872737 and CN109371705, the method according to the invention provides for the use of an intimate blend yarn formed by 65% by weight of polyester fibers and 35% by weight of cotton fibers, provides for carrying out a weaving phase with 2/1 twill weave and also the upholstery fabric has a weight of about 180-210 g/m.sup.2. This is particularly advantageous, indeed optimal, as it allows to obtain a fabric that is particularly suitable to be used for upholstery, in particular the weight of about 180-210 g/m2 combined with the 2/1 twill weave allow to avoid the leakage of the material to be covered or filled (in particular in the case of feathers or other stuffing), and at the same time the use of an intimate blend yarn with polyester fibers for 65% by weight and with fibers of, and in particular makes it compliant with sector regulations, and in more detail it allows to pass combustion the test described in California TB (Technical Bulletin) 117: 2013section 2.

[0102] The present invention has been illustrated in a preferred embodiment thereof, but it is understood that executive variations may be applied to it in practice, without other than departing from the scope of protection of the present patent for industrial invention.